OPTIMIZE YOUR SPRAY NOZZLE PERFORMANCE - BETE

OPTIMIZE YOUR SPRAY NOZZLE PERFORMANCEWITH MONITORING & MAINTENANCE

TABLE OF CONTENTS

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Monitoring & Maintenance • Systems Components Working Together • Damage

Maintain Performance & Reduce Waste • Symptoms • Maintaining & Cleaning Nozzles • Wear & Tear

Evaluating Nozzle Performance • Visual Inspection of Nozzle • Visual Inspection of Spray Pattern • Monitor Flow Rate & Pressure • Monitor System Performance & Effectiveness

BETE Engineering & Lab Services • BETE Application Engineers • Spray Laboratory • Computational Modeling • Special Testing

PERFORMANCE SPRAY ENGINEERING Spray nozzles may be a small component of complex

processes, but their performance is critical to success. Spray

nozzles that are not thoroughly inspected and regularly

evaluated for wear or damage can cause operations to fail

or lead to thousands of dollars in wasted resources. The cost

of scrap resulting from quality control problems, additional

chemicals and energy, unscheduled production downtime,

and extra labor can quickly escalate. Most spray problems are

avoidable through a simple nozzle maintenance program to

check for wear and clean or replace any identified problem

areas.

BETE’s mission goes beyond just selling spray nozzles. It is

to provide engineered spray process solutions that exceed

customer expectations in every detail. Our patented spray

technologies are quality inspected and field-proven to meet the

high standards of third-party certifiers.

We make tens of thousands of different products, including

automatic spray nozzles, air atomizing nozzles, misting

nozzles, tank washing nozzles, spray drying nozzles, spray

lances, fabrications, and automated spray systems. Expect

world-class customer service from project inception through

the delivery and maintenance of your final product. From

initial discussions to design, fabrication, and ongoing service –

we will make your project a success.

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MONITORING & MAINTENANCE

SYSTEMS COMPONENTS WORKING TOGETHER

Spray nozzles are highly engineered precision components designed

to provide performance functionality for a particular goal such as

cooling, coating, or cleaning. The nozzle’s quality ensures a complete

spray system with multiple components (pumps, filters, valves,

piping) will operate effectively and efficiently.

DAMAGE

Not only can damage, wear, corrosion, or clogging affect the nozzle’s

performance (system effectiveness) – it also affects the other

components of a spray system, potentially resulting in increased

energy costs, wasted resources, and unscheduled downtime.

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• Soaking/washing with appropriate cleaning fluids is the best method to

clean without damaging the nozzle.

• Always clean tips with a soft instrument such as a cleaning brush.

• Never use sharp instruments such as probes or picks. Even a tiny nick in

the orifice will result in degradation of spray performance.

• Ultrasonic cleaning baths can help clean small nozzles and orifices.

MAINTAINING & CLEANING NOZZLES

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SYMPTOMS

Pumps can run off their curves, filters can fail,

instrumentation becomes unpredictable, and

equipment can get damaged. Each scenario is likely

to result in unscheduled maintenance, higher energy

costs, process waste increases, and impact on the

manufactured products’ quality.

MAINTAIN PERFORMANCE & REDUCE WASTE

EXAMPLE OF NOZZLE WEAR OR EROSION (BETE NOZZLE P/N TF56XPN)

Note: 10% increase in orifice diam can result in more than a 20% increase in nozzle flow rate

Note: 20% increase in orifice diam can result in more than a 50% increase in nozzle flow rate

A header with Qty (20) x TF56XPN nozzles operating at 20 PSI (NEW)

(20) x 91.2 GPM = total 1824 GPM

A header with Qty (20) x TF56XPN nozzles operating at 20 PSI (10% orifice wear)

(20) x 20% increase = new total 2188 GPM

A header with Qty (20) x TF56XPN nozzles operating at 20 PSI (20% orifice wear)

(20) x 50% increase = new total 2736 GPM


EVALUATING NOZZLE PERFORMANCE VISUAL INSPECTION OF NOZZLE

Visual inspection can show signs of damage that may have occurred during installation or standard

operation. Though not always evident, a quick visual inspection can usually identify wear or corrosion.

Type of Nozzle NormalSpray Pattern

PoorSpray Pattern

Signs of Poor Performance

Flat Fans

• Flow becomes centered

• Coverage angle is reduced

Full Cones• Liquid centers

in cone• Coverage angle

is reduced

Hollow Cones• Pattern is not

precise• Flow rate

fluctuates

VISUAL INSPECTION OF SPRAY PATTERN

Streakiness, heavier sections, fluttering, or skewed/lopsided

spray patterns can all indicate that a nozzle is not operating as

designed or intended.

MONITOR FLOW RATE & PRESSURE

The flow rate and operating pressure drop of the nozzle are

directly related. If these values change from nominal, it can

indicate issues with the nozzle like clogging or excessive wear.

MONITOR SYSTEM PERFORMANCE & EFFECTIVENESS

Changes in overall system performance, such as temperatures, pollutant levels, and coverage, can indicate

nozzle issues like damage, clogging, or wear.


BETE ENGINEERING & LAB SERVICESBETE’s extensive resources and 70 years of experience are available to help you solve existing spray

problems and achieve process improvements. Our facilities include a spray laboratory, state-of-the-art

production machinery, rapid prototyping, computer modeling, an in-house foundry, and a staff with decades

of combined experience in diverse fields.

BETE Applications Engineers can assist you when your application requires a custom-designed nozzle,

involves precise spray performance, or unusual operating conditions. Our engineers have many years of

experience in nozzle design and process specifications.

SPRAY LABORATORY

BETE’s dedicated spray laboratory analyzes and characterizes sprays, spray nozzles, and their uses.

We measure common spray characteristics, including flow rate and pressure, liquid distribution, droplet

size, spray angle, and droplet velocity. Our team can build physical models of your process to help diagnose

problems or select the best nozzle application.

Examples of physical tests of nozzles:

• Flow visualization in pipes, ducts, and tanks.

• Applications-based testing to measure the effect of a spray either in or on a system. These include such

things as impact, coating uniformity, reach, wind drift, and spray effectiveness.


FREE SPRAY NOZZLE & SYSTEM AUDIT

On-site consultation to review your spray process, evaluate nozzle

performance, and assist in optimizing system performance.

NO-COST NOZZLE TESTING & EVALUATION (REASONABLE QUANTITY)

Conducted in our spray lab. Includes a test report generated to compare

evaluated wear to the original nozzle specification.

BETE NO-COST SUPPORT SERVICES

COMPUTATIONAL MODELING

BETE offers computer modeling of sprays and processes using ANSYS® FLUENT® computational fluid

dynamics software (CFD). Modeling a spray process can help select nozzles, operating conditions, and

positions when designing or improving processes. It can also identify the cause of problems in an existing

operation. Examples of our modeling include droplet trajectories and evaporation of sprays in ducts, wetting

of walls in furnaces, and mixing chemicals in pipelines.

Computer modeling, combined with physical testing in our laboratory, gives you confidence in your system

design or problem solution.

SPECIAL TESTING

Besides characterizing nozzles, BETE has set up many unusual tests, including:

• Study of erosion patterns in fluidized beds

• Pattern distribution of fire protection nozzles with simulated wind

• The spatial concentration of respirable droplets

• Comparison of flow rates and spray patterns using oil and water

• Effectiveness of tank washing nozzles

• Seal leak tests to ASTM A515 using helium

• Life cycle testing

• Strain gauge tests for pressure vessels

For more details on either option, please contact

us at [email protected] or 413-772-2166, Ext 5.


BETE Fog Nozzle, Inc.

50 Greenfield Street, Greenfield | MA 01301 USA

413-772-0846 | www.BETE.com | [email protected]

©2020 BETE Fog Nozzle, Inc. All rights reserved

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OPTIMIZE YOUR SPRAY NOZZLE PERFORMANCE - BETE

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